Predictive Modelling for Incremental Cold Flow Forming: An integrated framework for fundamental understanding and process optimisation

增量冷流成型的预测建模：用于基本理解和流程优化的集成框架

• 批准号: EP/T008415/1
• 负责人: Chris Pearce
• 金额: $ 157.15万
• 依托单位: University of Glasgow
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2020
• 资助国家: 英国
• 起止时间: 2020 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FT008415%2F1
• 关键词: Predictive; Modelling; Incremental; Cold; Flow

Incremental cold flow forming (ICFF) is a metal forming process for the production of high-quality, rotationally-symmetric, hollow engineering components as widely utilised by the aerospace, automotive and oil & gas sectors. In ICFF, a cylindrical preform is attached to a rotating mandrel and axially-translating rollers apply compression to the outer surface. This leads to extrusion of the workpiece material via significant plastic deformation. As a result of the incremental process - rollers are in contact with a small area of the exterior surface of the workpiece at any one time - the extrusion of the material occurs with significantly lower force than required for conventional forming processes. ICFF is thus well suited to high-strength, hard-to-deform materials. The process is "cold" as a coolant is applied where contact occurs between the workpiece and the roller. The deformation occurs significantly below the material's recrystallisation temperature. As a result, cold work hardening occurs leading to increased strength, stiffness and hardness of the final product. A significant advantage of ICFF over conventional forging and deep drawing is the flexibility it gives engineers to design complex components of varying size. ICFF can result in considerable cost savings via improved yields, reduced production times and improved material properties, as compared to standard manufacturing routes. Furthermore, ICFF allows for rapid prototyping to support virtual product design, thereby reducing development cost and driving innovation.Despite the significant advantages that ICFF has over conventional methods, considerable challenges remain. These must be overcome prior to its widespread adoption. Foremost is the unsatisfactory repeatability and reliability of the process; it can be unstable and failure of the material can occur. Controlling the complex ICFF process is challenging. This is compounded by the large number of process parameters and the highly nonlinear nature of the deformation. Critically, there is currently no accurate and robust model to elucidate the fundamental physical mechanisms that occur during ICFF. Without such a model, the application of ICFF to new products and materials will require costly trial-and-error component-scale testing and remain an art as opposed to a science. The primary aim of this collaborative research proposal between the Advanced Forming Research Centre (AFRC) and the Glasgow Computational Engineering Centre (GCEC) is to develop an engineering design framework to model ICFF. Understanding the response of materials to the loading regime imposed by ICFF is a key component of the model development. To this end, we will undertake a detailed materials characterisation study at the AFRC. The loading on the workpiece will be measured using a highly-instrumented, research-dedicated ICFF machine. In addition, a materials characterisation procedure for ICFF will be developed that will allow industry to test new materials for ICFF thereby reducing the need for costly ICFF trials.The computational model will build upon and significantly extend the existing framework provided by MoFEM - a state-of-the-art, general purpose finite element library developed within the GCEC. The model will account for all key features of ICFF, including significant deformations, contact between rotating parts, thermal effects and residual stresses. The highly non-linear and coupled nature of these processes makes modelling challenging. The modular nature of MoFEM allows us to focus on designing new, efficient and robust numerical methods for ICFF rather than developing the core of the library. The ability of the model to accurately simulate a range of ICFF applications will be demonstrated using component scale testing conducted at the AFRC. Finally the predictive capabilities of the model will be assessed by numerically optimising the process parameters to achieve a desired net shape.

增量冷流形成（ICFF）是一种金属形成过程，用于生产高质量，旋转对称，空心工程组件，该过程被航空航天，汽车和油气领域广泛使用。在ICFF中，将圆柱式预成式连接到旋转的曼德尔，轴向翻译辊对外表面进行压缩。这导致通过明显的塑性变形挤出工件材料。由于增量过程 - 滚子在任何时候都与工件外表面的一小部分接触 - 材料的挤出物的挤出力明显低于常规形成过程所需的力。因此，ICFF非常适合高强度，难以塑造的材料。该过程是“冷”的，因为在工件和滚筒之间发生接触的地方应用了冷却液。变形显着发生在材料的重结晶温度以下。结果，冷工作硬化会导致最终产品的强度，刚度和硬度提高。 ICFF比常规锻造和深度绘画的重要优点是，它使工程师设计了不同尺寸的复杂组件的灵活性。与标准制造路线相比，ICFF可以通过提高产量，减少生产时间和改进的材料特性来节省大量成本。此外，ICFF允许快速原型制作支持虚拟产品设计，从而降低了开发成本和推动创新。这些必须在广泛采用之前克服。最重要的是该过程的重复性和可靠性不令人满意。它可能是不稳定的，材料的故障可能会发生。控制复杂的ICFF流程具有挑战性。这是由大量的过程参数和变形的高度非线性性质更加复杂的。至关重要的是，目前尚无准确稳健的模型来阐明ICFF期间发生的基本物理机制。如果没有这样的模型，ICFF在新产品和材料中的应用将需要昂贵的试用组件尺度测试，并且与科学相比仍然是一种艺术。高级成立研究中心（AFRC）和格拉斯哥计算工程中心（GCEC）之间的合作研究建议的主要目的是开发一个工程设计框架来建模ICFF。了解材料对ICFF施加的载荷制度的响应是模型开发的关键组成部分。为此，我们将在AFRC进行一项详细的材料表征研究。工件上的负载将使用高度启发，研究的ICFF机器进行测量。此外，将开发出ICFF的材料表征程序，该程序将使行业能够测试新材料以进行ICFF，从而减少了对ICFF昂贵的试验的需求。计算模型将基于并大大扩展MOFEM（MOFEM）在GCEC内开发的最先进的通用有限元库。该模型将考虑ICFF的所有关键特征，包括显着的变形，旋转部件之间的接触，热效应和残余应力。这些过程的高度非线性和耦合性质使建模具有挑战性。 MOFEM的模块化性质使我们能够专注于为ICFF设计新，高效且可靠的数值方法，而不是开发库的核心。模型准确模拟一系列ICFF应用程序的能力将使用在AFRC上进行的组件量表测试证明。最后，该模型的预测能力将通过数值优化过程参数以实现所需的净形状来评估。

项目成果

Multifield finite strain plasticity: Theory and numerics

多场有限应变塑性：理论和数值

• DOI: 10.1016/j.cma.2023.116101
• 发表时间: 2023
• 期刊: Computer Methods in Applied Mechanics and Engineering
• 影响因子: 7.2
• 作者: Lewandowski K

The role of shear dynamics in biofilm formation.

剪切动力学在生物膜形成中的作用。

• DOI: 10.1038/s41522-022-00300-4
• 发表时间: 2022-04-29
• 期刊: NPJ BIOFILMS AND MICROBIOMES
• 影响因子: 9.2
• 作者: Tsagkari, Erifyli;Connelly, Stephanie;Liu, Zhaowei;McBride, Andrew;Sloan, William T.
• 通讯作者: Sloan, William T.